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TRS-05 Upgrade System Manual

1. O O O O a i a DN O ME PFT Es 5 ao O Ke a ae ADAN T lolo oyo E OI L Li OJO OO oyo FF 0 O 58 E O ale I oyo a a aa NJ JO o I T OO oyo COS olo __ I zo OO oyo III o o i I SIE ON o o w Iola oyo ES A O olo i TN 9219 boooooo0o0o0o00o00g0 mai RJ sa O O O D E e R L 90 ISI OR PG11 SI E X o s SkyAz l Equipment Solutions www skyazul com 301 371 6126 Component Installation 13 VViring information Power the TRS 05 wires on X1 2 and X1 3 will need to be added to the existing wiring Do not remove the existing vvire on these terminals Radio Load Cell vvires on signal sensor 1 and 2 Remove the existing vvires from terminal X1 34 X1 33 X1 24 and X1 23 and add the TRS 05 wire as shown Hardwired Anti Two Block Switch If the hardwired A2B switch is being used do NOT remove the existing wires from X1 39 and X1 40 Do NOT wire 7 and 8 from the TRS 05 Radio Anti Two Block Switch If one or two radio A2B switch es are being used remove the existing wires from X1 39 and X1 40 and add the TRS 05 wire as shown The second switch on signal sensor 4 does not need to be wired The TRS 05 software recognizes an A2B switch is connected to signal sensor channel 3 and 4 therefore if either switch is opened the signal is sen
2. 031 300 050 688 ANTENNA 918 MHz RCL 90 OTHER SENSOR 031 300 060 559 ANTENNA ASSY 918 MHz WHIP FORLOAD CELL FOR LOAD SENSOR 031 300 050 535 CONNECTOR SMA RIGHT ANGLE M FREVERSE POLARITY FOR LOAD SENSOR SkyAzul Equipment Solutions www skyazul com 301 371 6126 SkyAz l Inc y 200 W Main Street Suite 2A EN Middletown MD 21769 Phone 301 371 6126 EQUIPMENT SOLUTIONS Fax 301 371 0029 www skyazul com info skyazul com
3. AkyAz l EQUIPMENI SOLUIIONS INSTALLATION CALIBRATION and SERVICE MANUAL NOTICE SkyAzul makes no warranty of any kind with regard to this material including but not limited to the implied vvarranties of merchantability and or its fitness for a particular purpose SkyAz l will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information vvhich is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of SkyAz l SkyAzul reserves proprietary rights to all drawings photos and the data contained therein The dravvings photos and data are confidential and cannot be used or reproduced vvithout the vvritten consent of SkyAzul The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice s SkyAz l Inc dal 200 VV Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAzul Equipment Solutions www skyazul com 301 371 6126 TABLE OF CONTENTS 1 GENERAL INFORMATION 0 c cccccceeececesssceeceeeeeeeeeeeneenecuseeneeaseeaecesseneeaeeusecaeeeneeaseussenenessenesass 1 2 WARNINGS mesones OE o A ion o
4. ID Button Current position Modular CU 6 4 2 Software Setup the software for the output of the TRS 05 Modular System current Hold the ID button for about 33 36 seconds until all 4 green LEDS are solid and released ID button to set all the analog outputs for 4 20mA current SRyAz l Equipment Solutions www skyazul com 301 371 6126 10 Operator s Installation Service Manual PAT TRS 05 65 CENTRAL UNIT INSTALLATION The power supply will be from 10 30 volt DC The signal output of the TRS 05 is dependent on the placement of red bridges installed on the channel jumpers 1 for signal 1 2 signal 2 3 signal 3 and 4 signal 4 Each jumper has 4 bridge positions as follows 1 2 voltage output 0 5V required for the standard DS350 system 3 4 amperage output 4 20mA required for the modular DS350 system 5 6 digital output 7 8 A2B switch output 6 5 1 TRS 05 Installation on the DS350 modular system central unit Breather Element ad Remove breather element use a M21 wrench to hold the PG11 nut inside the central unit Insert PG11 strain relief and tighten nut Insert cable as shown so the shield will ground on the strain relief cone There should be about 12 inches of cable inside the central unit to make the proper connections 4 Connect to the central unit as shown below Refer to system vviring below SkyAzul Equipment Solutions www skyazul com 301 371 6126 Component Installation 11
5. Green LED 1 OFF No sensor is installed on channel 1 Yellow LED 1 ON Sensor 1 batteries are low and need replaced Note that the sensor is still operating correctly Green LED 2 ON Sensor 2 is installed and communicating correctly Green LED 2 FLASHING Sensor 2 is not communicating correctly Green LED 2 OFF No sensor is installed on channel 2 Yellow LED 2 ON Sensor 2 batteries are low and need replaced Note that the sensor is still operating correctly Green LED 3 ON Sensor 3 is installed and communicating correctly Green LED 3 FLASHING sensor 3 is not communicating correctly Green LED 3 OFF No sensor is installed on channel 3 Yellow LED 3 ON Sensor 3 batteries are low and need replaced Note that the sensor is still operating correctly Green LED 4 ON sensor 4 is installed and communicating correctly Green LED 4 FLASHING sensor 4 is not communicating correctly Green LED 4 OFF No sensor is installed on channel 4 Yellow LED 4 ON Sensor 4 batteries are low and need replaced Note that the sensor is still operating correctly receiver has a software error or the board has a component failure 4 1 2 Control Identification Sensor Channel 1 output jumper J4 Sensor Channel 2 output jumper J3 Sensor 3 Channel 2 output jumper J2 Sensor 4 Channel 2 output jumper J1 ID button power red sensor on line 1 4 left to right green E CURRE N LEDS 1 4 left to right yellow LEDS Green Heartbeat LED
6. VViring information Power the TRS 05 wires on X1 1 and X1 2 will need to be added to the existing wiring Do not remove the existing vvire on these terminals Radio Load Cell vvires on signal sensor 1 and 2 Remove the existing vvires from terminal X1 25 X1 36 X1 22 and X1 24 and add the TRS 05 wire as shown Hardwired Anti Two Block Switch If the hardwired A2B switch is being used do NOT remove the existing vvires from X1 31 and X1 32 Do NOT wire 7 and 8 from the TRS 05 Radio Anti Two Block Switch If one or two radio A2B switch es are being used remove the existing vvires from X1 31 and X1 32 and add the TRS 05 wire as shown The second switch on signal sensor 4 does not need to be wired The TRS 05 software recognizes an A2B switch is connected to signal sensor channel 3 and 4 therefore if either switch is opened the signal is sent to the central unit NO ZC A 1 en EN A M YA a tz ff f N J DS350 MODULAR LY 2 JJ UI VI YV J CENTRAL UNIT N V yA U N WF U los IN A X ka S LY IN JJ IN OR A m Kae ES a JS fN TT yes ON Es A a A ANS A ca Ta f IN NA K A N J M A JN Tv ta A I YW A Y AN F l L X a X N U 3 A OA Y 3 AS PA I PA Y 2 IVI ES e A NI Z a NS AN PAIN I FA D SkyAzul Equipment Solutions www skyazul com 301 371 6126 12 Operator s lnstallation Service Manual PAT TRS 05 6 5 2
7. the transmitter immediately lt 100milliseconds sends a two block signal condition to the receiver to be displayed on the console and lockout the crane movements if connected to solenoid The LED will flash rapidly during a two block condition and will stop flashing after 15 seconds when the switch goes into sleep mode While in sleep mode the receiver will stay in a two block or communication loss condition Sleep mode increases battery life by reducing the number of radio transmissions To wake the switch simply close the switch by lowering the weight 5 2 3 Wind Speed Sensor The sensor is delivered with a bracket support that allows the sensor to stay perpendicular to the ground through the boom angle range CONTACT CRANE MANUFACTURER FOR WELDING INSTRUCTIONS PRIOR TO WELDING ON BOOM The mounting pole is affixed to the boom tip at your discretion so that the anemometer sensor is mounted approximately a foot higher than the boom sheaves and will not interfere or be damaged by hoist lines or extension mounting or movement Affix the mounting pole to the boom tip or possibly the length cable anchor pin so the pipe supports the sensor It must be installed so that no part of the crane can disrupt the measurement of wind SkyAzul Equipment Solutions www skyazul com 301 371 6126 6 Operator s Installation Service Manual PAT TRS 05 5 2 4 Angle The angle sensor total range is approximately 105 and the zero point is adjustable in the
8. SkyAzul Equipment Solutions www skyazul com 301 371 6126 Operation 5 52 TRANSMITTER The transmitter has an LED that will flash when a signal is transmitted to the receiver Our system transmits an OK signal every one transmit per 4 sections via a frequency hopping spread spectrum transmission method This is to ensure accurate and consistent reception of data and to reduce the possibility of unnoticed failure The separate channels greatly reduce the probability of failure due to external interferences The receiver cycles through the three missed data packets when software logic and or lost signal system will indicate a communication error 5 2 1 Load Cell The load cell transmits once every 1 to 2 seconds when in standby and 2 times a second when the load changes It will continue at 2 times a second for less than a 1 minute before dropping back to one transmission every 1 to 2 seconds There is no time it goes to sleep Note To extend battery life remove batteries from transmitter s if load cell s will not be used for extended periods of time Reinstalling batteries into the transmitter will not reguire a set up 9 2 2 A2B The PAT radio Anti two Block A2B system works to prevent a two block condition using a weight and switch During normal operation the weight closes the A2B switch The transmitter has an LED that flashes approximately every 2 seconds when the switch is transmitting If the weight is lifted and the switch opens
9. follovving steps 1 Installing the load cell sensor refer to 7 1 Install Sensor if not complete Zero the load cell The zero point adjustment will have an even affect across the entire range for example 200 Ib at both low and high loads 3 Adjust the gain to a 70 permissible load The gain adjustment will have only a small effect on light loads but a large effect on heavy loads Note If an incorrect menu is activated or the button is released accidentally simply cycle the power and start over Note When the system is in calibration mode the RCL system NOT in operation therefore crane operating guide line and load charts must be followed during calibration mode or other crane operations NOTE The unit will remain in main or auxiliary calibration mode until power is cycled off on After completing the main load cell calibration cycle power off on and complete the auxiliary load calibration Main load cell calibration Press and hold the ID button for 43 46 seconds until the 1 yellow and green LED will begin blinking and release the ID button The 1 yellow and green LED will become solid showing the receiver is now in calibration mode for the main load cell on channel 1 Complete sensor zero and gain adjustments in this section Auxiliary load cell calibration Press and hold the ID button for 46 49 seconds until the 2 yellow and green LED s will begin blinking and release the ID button The 2 yellow and green LED wil
10. light simultaneously with the engaging of the lock out solenoids if installed LED Sensor Low Battery 1 through 4 yellow When the light goes off it indicates that the battery of the sensor 1 4 transmitter needs to be replaced 10 2 2 Repeater The red power LED should be on after switching on the repeater from the crane ignition switch the system starts with an automatic test of the repeater board LEDs and electronic components The other red LED blinks when the repeater is transmitting a signal This can be compare to the load cell transmitter when sitting side by side the repeater module should transmit immediately after the load cell 10 3 TROUBLESHOOTING MOISTURE The receiver and repeater contain electronic components and have an IP65 protection rating These electronic components cannot be designed to withstand exposure to moisture over a longer period of time If you find water or moisture inside any of the housings the source for the water ingress has to be detected and corrected to ensure proper operation There are two major possibilities for the occurrence of excessive moisture inside an enclosure 1 Water ingress caused by a cracked or broken housing or lid or a defective gasket 2 Condensation This outline gives instructions for detecting the cause for excessive moisture by using simple troubleshooting methods and how to prevent the moisture ingress from happening again SkyAzul Equipment Solutions www skyazu
11. located just under radio module softvvare chip radio module 031 300 300 024 00 Baud odule 144 SXCITE SkyAzul Equipment Solutions www skyazul com 301 371 6126 4 Operator s Installation Service Manual PAT TRS 05 Heartbeat LED When blinking this small surface board mounted green LED indicates the system is operation properly ID button The red ID button located below the software chip on the receiver board is used to setup the sensor transmitter to the receiver 5 OPERATION 51 RECEIVER Upon switching on crane ignition switch the system starts with an automatic test of the receiver board LEDs and electronic components The red power LED should be on and the green LEDs that sensors have been linked to should also be on If an alarm condition exists investigate and clear the condition before operation and using the system During the normal operation of the system the POWER and SENSOR ON LINE if linked to a sensor LEDs should be on POWER LED The POWER LED shows that the receiver is getting power from the crane The receiver is on any time the crane is operating and supplying power to the system SENSOR ON LINE LED The SENSOR ON LINE LED indicates the status of communication of the transmitter s During normal operation of the system the LED will be on The LED will flash if communication or transmission between the sensor transmitter and the receiver is interrupted or lost The system should not be operated
12. zero point of the load cell place the load cell on the ground and ensure that no load on the load cell including any hook block lengths of cable etc The software will only allow the load cell zeroed when there is no load on the load cell If there is a load on the load cell the software will define this as a gain adjustment What is the load displayed on the console Does the load need to increased or deceased The red LED next to the yellow LED defines if the load will increase RED LED ON or decrease RED LED OFF If the RED LED ON pressing the ID will increase the load When the ID button is released the RED LED goes OFF Pressing the ID button will now decease the load When the ID button is released the RED LED goes ON Press the ID button until the displayed load is zero For the DS350G standard system if the load can NOT be zeroed the Additional Zero Point Adjustment for the DS350G standard system must be complete The LEDs will not change after zero point has been set SkyAz l Equipment Solutions www skyazul com 301 371 6126 18 Operator s Installation Service Manual PAT TRS 05 9 2 LOAD SENSOR GAIN ADJUSTMENT TO A 25 PERMISSIBLE LOAD To calibrate the gain of the load cell a Known load must be lifted Check the load display by lifting a load of known weight The accuracy of the load indication shall be within the tolerance of SAE J376 refer to complete SAE standard before testing Refer to Accuracy a
13. GES 9 3 1 Wind Speed Output __ Output Speed mph DN L 0 mph 20mA_ 50 mph 9 3 2 Load Cell Output Load Cell default range adjustable via calibration Output Load P 25V 100 20mA 100 Note Pending load cell type 2 5V 100 of load cell range 7 5T or 22 5T 20ma 100 of load cell range 7 5T or 22 5T 9 0V 2 1009 of load cell range 7 5T or 22 5T 9 3 3 Angle Output Output Degrees Voltage 3 125V 1 875V Current 20mA 0 APS 1 9V 1 8V 0 90 180 SkyAz l Equipment Solutions www skyazul com 301 371 6126 20 Operator s Installation Service Manual PAT TRS 05 10 SERVICE AND TROUBLESHOOTING 10 1 SERVICE Daily maintenance of the system consists of inspecting 1 The electrical wiring connecting the various parts of the system 2 If electrical wiring is damaged it shall be replaced immediately 3 If the insulation is worn on the electrical wiring or antennas are damaged these parts shall be replaced 4 A damaged or punctured housing or cover must be replaced immediately to prevent ingress of water and damage to the internal circuitry Other than correcting the problems identified in the Malfunctions Table and replacing faulty mechanical parts and cables no other repairs shall be made 10 2 TROUBLESHOOTING 10 2 1 Receiver After the onboard diagnostics have been performed follow these guidelines Power LED does No power to Make
14. LEDs solid All 4 yellow LEDs blinking All 4 yellow LEDs solid blinking yellow amp green LEDs 1 blinking yellow amp green LEDs 2 blinking yellow amp green LEDs 3 blinking yellow amp green LEDs 4 blinking yellow LED 1 blinking yellow LED 2 blinking yellow LED 3 blinking yellow LED 4 LEDs off no 1 4 left to right yellow ODA Sr ds LEDS Green Heartbeat LED 7 located just under radio module softvvare chip radio module 031 300 300 024 SRyAz l Equipment Solutions 00 Baud nodule ill www skyazul com Indication Indication Starts Sec Ends Sec 3 6 6 9 9 12 12 15 16 19 19 22 22 25 25 28 29 32 38 36 3 40 40 43 43 46 46 49 50 53 53 56 56 59 59 63 63 66 67 70 1 301 371 6126 Component Installation 9 6 4 SENSOR OUTPUT SETUP The sensor output is setup for the hardvvare bridge place on jumpers 1 amp 2 as shown below for the load cells and software use the ID button software output If the hardware and software do not match an error vvill occur 6 4 1 Hardware Install the bridge in the in the correct position modular system current or standard system voltage on jumpers 1 and 2 as show above If a sensor is not installed the bridges and jumpers will not effect the operation of the unit AZB 4 7K aes 1 CH eg 117 TIE YS iith p M AER m 1 u M I A M H DR NS We et KA E ei E J We a c EE 210 a e an 9
15. TRS 05 Installation on the DS350 standard system central unit Metal shaving inside the central unit could cause a short or damage electrical components inside the central unit Use some type of protective plastic cover to shield the board from metal shavings drill a 23 32 0 718 hole in the central unit housing in the location shown Clean all metal shavings from the central unit Insert PG 11 strain relief and tighten nut Insert cable in the strain relief as shown leaving about 12 of wire in the central unit The shield will ground on the strain relief cone and strain relief will be tightened around the red white insert hay ASJ
16. a OA A 1 3 IFEATURES E 2 A IS TEN DESCRIPTION aia 2 Ay aa A 2 PPP A Te 3 Aza COMO is sail sc O Mi Non ac 3 5 OPERA MON E 4 AAA A E E E 4 3 2 VAS MLS Dy a aE paneer ater EE EE E E E 5 JA E o i TE 5 Ee 5 aza A A 5 o mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmrmmmmmmmmmmmmmmmmmmmmmmmmmmmm mmmmmmmmmmmmmmmmmmmmmmmmmmmmmma 6 SAN e o ei OO 6 6 COMPONENT INSTALLATION iii RR RE RR RE RR RR 7 A e E o seran T 02 ICO T 0 9 TRO U5 Setup OVELV OW sra 8 6 4 Sensor Output Getunp ec oso nn nn nn nn RR REPRE RR RR RR RR RR nn 9 Oal ANE mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmrmmmmmmm mmmmme 9 OM 2 OV EE 9 6 5 Central Unit Installation ooncocconnconconnconnonncnncornonnnonnnnnonronnnonnonnnnnnonnonnnonnnnnnnanonnnnnnenanenoos 10 6 5 1 TRS 05 Installation on the DS350 modular system Central unt 10 6 5 2 TRS 05 Installation on the DS350 standard system central unt 12 6 6 FECA INSTALA HON EEN 14 c Wind l Leen ee eee ener ee ree race eee ee ae reer 14 7 TRS 05 SENSOR INSTALLATION HE 15 TA TAStalkSensor Transmite mm 15 7 2 Uninstall Sensor Transmitter oooccoccconcccncnccociocnconoonnonncnnonanonrnonnnnnonronnnonronnnnnnennrnnnenronnnannnnnnns 15 8 LOAD CELL INSTALLATION cccccceccceeesseeeeceeeeeeeeneeneceeeneesseesecaeeeneeaeeuaeeeesenseneeeeseaseaesenenes 15 9 SENSOR CALIBRATION ME 16 91 Load S EE e Re Le 17 9 2 Load Sensor gain Adjustmen
17. ase the ID button The receiver begins to search for a transmitter ID code On the load sensor transmitter remove the card from the batteries or remove two batteries for 10 seconds and replace them In less than 10 seconds the 1 green LED will become solid when the transmitter is linked Auxiliary load cell channel 2 Press and hold the ID button for 6 9 seconds until the 2 green LED s will begin blinking and release the ID button The receiver begins to search for a transmitter ID code On the load sensor transmitter remove the card from the batteries or remove two batteries for 10 seconds and replace them In less than 10 seconds the 2 green LED will become solid when the transmitter is linked NOTE A new sensor or transmitter maybe install over an existing sensor on a channel when this occurs the previous link ID code are removed from memory and the new one stored 7 2 UNINSTALL SENSOR TRANSMITTER If a sensor is setup on the channel the LED will be ON press and hold the ID button 16 28 seconds through the Install Sensor mode blinking LEDs1 4 until the correct 1 4 LED is solid When the correct LED is solid channel to be uninstalled release the ID button The sensor for the selected channel LED 1 4 will be uninstalled and the system will be in normal operating mode As the ID button is held 16 28 seconds through the Install Sensor mode blinking LEDs1 4 and released at the solid LED the following actions will occur Gre
18. e TRS 05 receiver module should be mounted so the operator can view the LED s Securely attach the receiver onto a solid surface using the mounting holes 463 1171 4 00 1007 poo 97 4 aco 133 TEE dria cota V h Sere 2 Z na ree Spa ao kn nej ie Ta ler US ZE 4 32 Hi me mal a ts r E TRI i 1 54 139 Pwr 10 200C E GROUND 1 Pwr J0 200C 3 KGROUND 2 POUMD 4 SIGNAL SENSOR 3 KGROUND 5 KGROUND g SIGNAL SENSOR 1 amp SIGNAL SENSOR E 5 gGPHUND 7 GROUND 3 SIGNAL SENSOR 3 has e 3 GROUND 5 SIGNAL SENSOR 3 10 SIGNAL SENSOR 4 o SIGNAL SENSOR 4 11 FELAY OUT CABLE ASSEMBLY lu PELAY OUT MGITAL INPUT Power cable connections are show above 6 2 REPEATER The repeater module is mounted on the boom tip in line of sight to the receiver and the load cell The main purpose of the repeater is to receive and transmit the load cell ID code of the load cell during operation If the load cell line of sight is obstructed by a barrier i e wall or building the repeater should prevent and signal loss Power cable connections PIN 1 UB 9 to 30VDC PIN 2 GND SkyAzul Equipment Solutions www skyazul com 301 371 6126 63 TRS 05 SETUP OVERVIEVV Operator s Installation Service Manual PAT TRS 05 This section is a basic overvievv for the following Sections TRS 05 Sensor Output Setup and Load Sensor Calibration Press and
19. en LED 1 solid Uninstall sensor 1 Green LED 2 solid Uninstall sensor 2 Green LED 3 solid Uninstall sensor 3 Green LED 4 solid Uninstall sensor 4 8 LOAD CELL INSTALLATION NOTE After installation the load cell will need to be zeroed with no force applied and adjusted to a permissible heavy load The load cell and plates are installed at the dead end of the wire rope that is being used to lift the load The appropriate pins length and diameter for the type and size of socket block or ball must be used Ensure that the correct pin used is rated for the maximum line pull capacity and the side load plates will be straight when attaching the dead end lug and the load cell Install the side plates using the 2 1 4 pin so the pin head is on the antenna side Ensure all safety pins are installed properly with washers and bushing to fit the hole diameter and pin length SkyAzul Equipment Solutions www skyazul com 301 371 6126 16 Operator s Installation Service Manual PAT TRS 05 9 SENSOR CALIBRATION The calibration process should only be preformed when necessary While the ID button is held or in the calibration process the sensor outputs will not correctly indicate the status of other installed sensors Correct operation vvill return vvhen the menu is exited or calibration process is complete or system is povvered off on The load cell must be calibrated to ensure accuracy The load sensor calibration is completed complete the
20. hold ID button release the button at the desired indication or the number seconds defined in the follovving table The follovving table can be use as a quicR reference guide vvhen setting up the sensors on the TRS 05 and calibrating the load cell NOTE If an incorrect menu is activated or the button is released accidentally simply cycle the power and start over Menu Selection Release ID Button Install setup sensor on channel 1 Install setup sensor on channel 2 Install setup sensor on channel 3 Install setup sensor on channel 4 Uninstall a sensor on channel 1 Uninstall a sensor on channel 2 Uninstall a sensor on channel 3 Uninstall a sensor on channel 4 Set all the analog outputs for voltage 0 5V Set all the analog outputs for 4 20ma Set all the analog outputs for voltage 1 9V Set all the analog outputs for voltage 0 9V Calibrate load angle sensor on channel 1 Calibrate load angle sensor on channel 2 Calibrate load angle sensor on channel 3 Calibrate load angle sensor on channel 4 Remove all sensors and calibrations No action performed No action performed No action performed Exit No action ID button LEDS power red sensor link 1 4 left to right green indication of load adjustment up red LED lit down red LED off Indication blinking green LED 1 blinking green LED 2 blinking green LED 3 blinking green LED 4 solid LED 1 solid LED 2 solid LED 3 solid LED 4 All 4 green LEDs blinking All 4 green
21. if the SENSOR ON LINE LED is flashing If the LED is off no sensor is linked to this channel LOW BATTERY LED The lovv battery indicator will light indicating that you have a limited time to operate before the sensor battery life ends When the battery level is to the point that it is too lovv to operate the system will stop functioning Use any off the shelf alkaline C cells Duracell Eveready etc ALARM LED This LED will light simultaneously with the engaging of the lock out solenoids if installed Test the electronics Cycle the power to the system each LED on the receiver will light for 2 seconds when the system is povvered All of the indicator lights must come on or the system is not functioning properly If any light does not function do not use the system until it has been repaired Refer to receiver operating manual for pre operational inspection If a green sensor on line LED starts to flash this means a sensor is installed and the communication link has been lost When communication has been lost to a load cell the receiver will output the maximum voltage signal for the output sensor 9VDC If a low battery LED is on replace the batteries in the linked transmitter refer to Battery Replacement The TRS 05 setup calibration procedure allows the operator to input the type of sensors being used and adjust the zero point and output adjustment of a load sensor The operator must complete the setup procedure for each sensor
22. l become solid showing the receiver is now in calibration mode for the auxiliary load cell on channel 1 Complete sensor zero and gain adjustments in this section A2B calibration No calibration necessary for A2B Wind speed sensor calibration No calibration necessary for wind speed sensor Angle sensor calibration The angle zero point may be adjusted in the same manner as the load cell zero point is adjusted There is no gain adjustment for the angle sensor SkyAzul Equipment Solutions www skyazul com 301 371 6126 Sensor Calibration 17 LED on increase load LED off decrease load Or r mama A A HIRSCHMANN OX Cite 900 MHz 9600 Baut a hale ness Module TELET Power on arts a FR B dA Blinking yellow and green LED calibrate channel sensor 1 Blinking yellow and green LED calibrate channel sensor 2 AA Ta Calibration mode is when the ID button is used to increase or decrease the displayed load to match the actual load If the alarm LED is on when the ID button is press the displayed load will increased until the button is released and the LED will go off If the alarm LED is off when the ID button is press the displayed load will decreased until the button is released and the LED will come on Next the zero point and gain adjustments must be setup The zero point must be a no load adjustment and the gain adjustment is at least a 70 permissible load adjustment 9 1 LOAD SENSOR ZERO POINT To set the
23. l com 301 371 6126 22 Operator s Installation Service Manual PAT TRS 05 11 MAINTENANCE The only maintenance required is to change the batteries when required Also check the mounting hardvvare daily to ensure that there is no damage Replace any damaged parts before operating the crane Recommendation We recommend lithium batteries for cold temperatures below 20C Alkaline batteries are rated from 20C to 54C 4F to 130F Lithium batteries are usually rated from 55C to 85C 67F to 185F We recommend the TL 2200 S available from Newark com 11 1 BATTERY REPLACEMENT To replace the batteries remove the 4 screws from the transmitter housing During battery replacement use caution when opening the battery cover and transmitter to avoid damage to the gasket causing moisture ingress which could corrode the batteries and terminals Inspect the gasket surface on the transmitter for nicks or other damages that may prevent the gasket from sealing If it appears to be damaged a replacement gasket should be installed Install 4 fresh batteries into the proper location and direction as indicated on the battery holder Make sure that the cardboard tube is installed as shown Te d W WODVOMANYJY 5glvd 1300 Lire al e i Oi V non 3 0 8 1 4 0 6 1299 gi ibn I 9 4 v vw bi Tv nm INSTALLED BATTERIES Visually inspect the gasket and tighten the Insert the batteries and cardboard sleeves Ensure battery cover in place wi
24. labeling or signaling is to be provided indicating that these accuracy criteria cannot be met The weight of the load being lifted and all additional equipment such as blocks slings sensors etc also referred to as working load Test Requirements System tests are to be conducted using an appropriate configured crane and specified load rating chart For system calibration three or more test radii or boom angle are to be employed to establish compliance with the accuracy section above Test loads shall be as near as is practical to minimum mean and maximum values within the operating limits One of the following test methods or equivalent is to be used Known Weight Test load to be applied by suspending known weights accurate to 1 If the weights of all additional equipment such as blocks slings sensors etc are included in the test load the total load is to be known to an accuracy of 1 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Sensor Calibration 19 Fixed Anchor Deadman Test load to be applied by hoisting against a fixed anchor or deadman equipped vvith a means for measuring loads accurate to 1 If the weights of all additional equipment such as blocks slings sensors etc are included in the test load the total load is to be known to an accuracy of 1 The system accuracy is to be determined from the following formula Indicated Load x 100 of Load Actual Load 9 3 SENSOR OUTPUT RAN
25. nd Test Requirements below before completing the calibration Ideally the load should be as heavy as permissible given the load cell and crane configuration chosen When calculating the load on the load cell it must be remembered to add the weight of any headache ball hook block and rope used depending on load cell location The software automatically switches from zero point to the gain adjustment when a load greater than 25 of the maximum load cell value is applied to the load cell View the load reading on the display and use the ID button to increase or decrease the reading as necessary in the same manner as was used to adjust the zero point When calibration is completed re check the zero point a light load hook block and rigging a medium load and the load used for the gain adjustment If a new load cell is installed or the load cell is uninstalled and re installed the calibrations must be repeated Installing a load cell causes the calibrations to revert to their default settings Exit the calibration mode by turning off the power supply to the TRS 05 Calibration settings are saved to long term storage when the power turns on 9 2 1 Accuracy and Test Requirements Accuracy The accuracy of the load indicating system is to be such that the indicated load is not less than 100 of the actual load nor more than 110 of the actual load Where the system cannot meet the accuracy criteria at the lower load range conspicuous
26. peration of 4 sensors Minimum of 500 feet LOS Easily and clearly shows the operator required information for the radio sensor o Power LED red o Link condition LED green LED on sensor installed and linked LED flashing installed but link or communication has been lost and LED off sensor not installed o Low battery indication LED yellow o Warning of Error LED red 4 SYSTEM DESCRIPTION 41 RECEIVER MODULE The receiver module has the following functions e Visual indication of receiver power radio links Sensor on line sensors low battery and alarm conditions e Installs uninstalls a sensor e Allows a zero point and output adjustment of a load sensor Red Power LED Red Alarm LED Sensor On Line Green LED 1 Green LED 2 Green LED 3 Green LED 4 Ea PA 1 RADIO RECEIVER Yellow LED 1 ia s PAT TRA CA Ty dar cara pg An i a Sz t sri Lora Yellow LED 2 Le Se a Rus b Ce D deeg be Ll Nj Tram Swen mp al Beie TAS re xd 7 et DE rastu Rief Metered a eis Yellow LED 3 AA Yellow LED 4 Sensor Low Battery SkyAz l Equipment Solutions www skyazul com 301 371 6126 System Description 3 4 1 1 LEDs Red Power LED Power is applied to the circuit board Red alarm LED An installed sensor is indicating an alarm or communication as been lost to an installed sensor Green LED 1 ON Sensor on channel 1 is installed and communicating correctly Green LED 1 FLASHING sensor 1 is not communicating correctly
27. softvvare in the angle calibration menu With no softvvare adjustment the angle range will allow a 15 to 907 range but if the angle sensor is zeroed at 5 5 becomes 0 your angle range will be 10 to 95 Therefore when affixing the mounting plate to the boom make sure you will be able to get your desired angle range for your application 53 REPEATER The purpose of the repeater is to reduce the possibility of a communication loss error by receiving the load cell transmitted ID code and re transmitting the same ID code out to the TRS 05 To do this the repeater is positioned at the boom tip up the hoist rope from the load cell and up the boom from the TRS 05 If the load cell does not have a direct line of sight or blocked by a wall structure from the TRS 05 then there is less chance of the signal absorption interference The repeater is setup from the factory to repeat signals from the load cells to the TRS 05 receiver TRS 05 can receive both transmissions load cell and repeater and output the load signal to the system computer After switching power on to the repeater from the crane ignition switch the system starts with an automatic test of the repeater board LEDs and electronic components The red power LED should be on and other red LED blinks when the repeater is transmitting a signal SkyAzul Equipment Solutions www skyazul com 301 371 6126 Component Installation 7 6 COMPONENT INSTALLATION 6 1 RECEIVER Th
28. sure the receiver is getting power from the crane not light receiver Check wiring Ensure correct polarity of the power Open receiver and check green blinking status of LED Communication Low battery Verify which sensor is causing the error by looking at error the communication error screen Replace batteries Communication Faulty sensor Verify which sensor is causing the error by looking at error the communication error screen Verify that the LED on the sensor is blinking Communication Poor reception Verify which sensor is causing the error by looking at error the communication error screen Verify that the LED on the sensor is blinking Verify that the sensor is line of sight to the receiver Communication Sensor not Install the sensor on the receiver See adding sensors error installed Communication Poor Remove potential interference sources from the area error communication Mount the receiver in a different location caused by interference does not flash does not flash SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Troubleshooting 21 LED Sensor On Line 1 through 4 Green Indicates the status of the communication link between sensor 1 4 transmitter and the receiver Failure of the communication link will cause the Green LED to flash and the signal output will change to the following condition e 4 20mA output will be OmA Alarm LED Red Indicates a lock out condition This LED will
29. t Solutions www skyazul com 301 371 6126 Spare Part Numbers SS dy IA Ag 3 S e s LA TA a G t 031 300 050 29 A2B Mounting standoff 031 300 050 264 A2B mounting plate 031 300 050 272 Lynch pin SRyAz l Equipment Solutions www skyazul com 301 371 6126 27 28 Operator s Installation Service Manual PAT TRS 05 031 300 050 321 031 300 050 480 Mounting pole Anemometer mounting plate em e geg ra 031 300 050 322 031 300 060 586 Pin Transmitter 031 300 050 323 031 300 050 507 Retaining pin Sensor SkyAzul Equipment Solutions www skyazul com 301 371 6126 Spare Part Numbers 29 031 300 060 607 SENSOR ASSY WINDSPEED RADIO MTG PLATE SPREAD SPECTRUM 031 300 050 688 ANTENNA 918 MHz RCL 90 SkyAzul Equipment Solutions www skyazul com 301 371 6126 30 Operator s Installation Service Manual PAT TRS 05 12 4 Angle fh HIRSCHMANN 031 300 060 592 Sensor Angle w Transmitter 031 300 050 577 Plate Radio Angle Mounting SkyAz l Equipment Solutions www skyazul com 301 371 6126 Spare Part Numbers 31 12 5 Antenna options Mount antennas in identical positions and in a direct line between transmitter and receiver ensuring that no obstructions will interfere with the transmission of the radio signal 031 300 050 671 ANTENNA 918 MHz FOR TRSOSASSEMBLY 060 576 VVHIP ELEMENT 031 300 050 672 ANTENNA 918 FOR CONSOLE MHz MAGNETICBASE 13ft LONG WIRE FOR CONSOLE
30. t to a 25 poermssibleload sss 18 9 2 1 Accuracy and Test Requirements sra road Anas kA ln o coseeceenatenserenesondenaes 18 9 3 Sensor Qutput E ue E 19 DA WMA peca O i ees 19 GE Ce Fe 0 EEN 19 Sl ANGE er mmmmmm mmmmmmmmmmmm rr rmrmrmrmrmrmrmrmrmrrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmrmmrmr na 19 10 SERVICE AND TROUBLESHOOTING iii nn RE RR RR 20 NOS SCIC El EE 20 NE WOU SS NOON EE 20 PA SSA E E 20 10 22 Oj P A Pe OP o O O 21 10 3 Troubleshooting de dt 21 11 MAINTENANCE E 22 11 1Battery Replacement EE 22 12 SPARE PART NUMBER Sttiissiscessevccscesccdacentenidccncaxeccceecneactananasevsntsennceecsewcsansdsanscevteancanssatencsaesanees 23 12 WI COI EE 23 RE mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmrmrmrmmmmmm mm mmmmmmmmmrmrmrmrmrmmmmmmmmmmmmmmmmmmmmmmmmmmmm 25 SkyAz l Equipment Solutions www skyazul com 301 371 6126 12 3 Wind 12 4 Angle Operator s Installation Service Manual PAT TRS 05 IZS ANN Na OD NOS ia patri oi ch non n r E ao r nd SkyAz l Eguipment Solutions www skyazul com 301 371 6126 General Information 1 1 GENERAL INFORMATION The PAT TRS 05 system interface has been designed to use radio communication for load sensors The TRS 05 receives a radio signal from a transmitter sensor and converts a signal as a replacement for the existing hardvvired sensor Review system operator s manual for system description and operation All system functions and error codes
31. t to the central unit UJ SON A A G pr Oc 7 Ll gt gt 7 O Ge SC Ae 71 L ve l N U 3 NO O IN NO AY TT 0 6 SIGNAL SENSOR 2 25 SIG FORCE AUXILIARY LOAD CELI 7 RGROUND A2B GNL SIGI ADD A2B Q N C dl Nf YV de N UL CABLE ASSEMBLY IO IRS 05 AUXILARY A2B SkyAzul Equipment Solutions www skyazul com 301 371 6126 14 Operator s Installation Service Manual PAT TRS 05 66 IFLEX INSTALLATION 6 6 1 Wiring Diagrams gt LMI CENTRAL UNIT REF el D CH i Es wi NOTES O gt CUT TAPE AND STOW WIRE WIND FORCE SIGNAL o ANALOG INPUT 3 IF IFLEXS ANALOG INPUT 2 IF IFLEXZ 2 A 0 5 55 TELEMETRY RECIEVER TRSO5 031 300 060 597 LS SkyAz l Equipment Solutions www skyazul com 301 371 6126 TRS 05 Sensor installation 15 7 TRS 05 SENSOR INSTALLATION 74 INSTALL SENSOR TRANSMITTER Setup the sensors on the 4 channels with the sensor as described below and mark the sensors i e CH1 MAIN or LOAD 1 Note The following list corresponds with the installation wiring in this manual Tip bring the sensor close to the TRS 05 receiver cab not necessary but will simplify the procedure Remove the battery covers from the sensors to be installed Main load cell channel 1 Press and hold the ID button for 3 6 seconds until the 1 green LED S will begin blinking and rele
32. th the 4 cover screws the LED starts to flashing when the batteries are first install in a force transducer transmitter LED comes on for 1 second off 1 sec and back on for 1 sec then begins to flash SkyAzul Equipment Solutions www skyazul com 301 371 6126 Spare Part Numbers 23 12 SPARE PART NUMBERS 12 1 Receiver 031 300 050 67 1 ANTENNA 918 MHz FOR TRSOSASSEMBLY 060 576 WHIP ELEMENT 031 300 050 672 ANTENNA 918 MHz MAGNETICBASE 13 long wire 031 300 060 597 RADIO RECEIVER TRSO5 2SPREAD SPECTRUM W NEG VOLT OUT SkyAzul Equipment Solutions www skyazul com 301 371 6126 24 Operator s Installation Service Manual PAT TRS 05 031 300 060 596 TRS 05 REPEATER 031 300 060 601 CABLE ASSY 15 2 COND SS 031 300 050 688 ANTENNA 918 MHz RCL 90 20AWG W 12 SKT DEUTSCH SkyAzul Equipment Solutions www skyazul com 301 371 6126 Spare Part Numbers 25 031 300 060 609 SENSOR ASSY FORCE TRANS 45KRADIO SPREAD SPECTRUM REV 031 300 050 535 CONNECTOR SMA RIGHT ANGLE M FREVERSE POLARITY 031 300 060 559 ANTENNA ASSY 918 MHz WHIP FORLOAD CELL 122 A2B 031 300 060 593 Radio A2B transmitter assembly SkyAzul Equipment Solutions www skyazul com 301 371 6126 26 Operator s Installation Service Manual PAT TRS 05 HRS CH GM 031 300 060 586 Antenna only Radio A2B transmitter 031 300 050 688 031 300 050 763 Neoprene rubber gasket 031 002 060 022 Radio A2B switch SkyAzul Equipmen
33. will remain the same for the DS350 system This manual vvill describe the operation sensors setup and calibration and additional troubleshooting points for the TRS 05 2 VVARNINGS Review system operator s manual for system warnings The responsibility for the safe operation of the crane remains with the crane operator who must ensure that all warnings and instructions supplied are fully understood and observed Prior to operating the crane the operator must carefully and thoroughly read and understand the information in this manual and the system manual to ensure that the operation and limitations of the system and the crane are known The system can only work correctly if all sensors transmitters have been properly set For correct setup the operator has correctly complete all procedures in this manual the system manual and the setup procedure in accordance with the real rigging state of the crane To prevent material damage and serious or even fatal accidents the correct adjustment of the system has to be ensured before starting the crane operation Always refer to operational instructions and load charts provided by the crane manufacturer for specific crane operation and load limits SkyAzul Equipment Solutions www skyazul com 301 371 6126 2 Operator s Installation Service Manual PAT TRS 05 3 FEATURES The PAT TRS 05 has the following features Can be hardwired to most PAT systems and certain crane systems VVireless o

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